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The characteristics of hydrothermal carbonization hydrochar derived from cattle manure including excrements and lignocellulosic biomass were analyzed. The effects of hydrothermal carbonization were evaluated by varying the reaction temperatures in the range of 180~240 °C. The hydrochars were evaluated with respect to their usefulness as renewable fuels via physicochemical analysis and pyrolysis processes. As reaction temperatures increased, the fractions of fixed carbon in proximate analyses, carbon elements in ultimate analyses, and higher heating values of hydrothermally carbonized biochars increased in correlation with the primary reactions of coalification. Various correlations were derived with the characteristics of hydrochars in order to be utilized for operating and designing HTC reactors for cattle manure. The correlation between the O/C and H/C ratios was deduced on the basis of a van Krevelen diagram. The interaction equation was represented with the increased fraction of HHV compared to the reaction temperature of hydrothermal carbonization. The ultimate correlation for the estimation of higher heating values was suggested for HTC hydrochars. Moreover, the pyrolysis characteristics and kinetic parameters of the cattle manure and hydrochar were deduced by utilizing a multi-step kinetic model scheme. As the HTC reaction temperature increased, the global activation energy and the pre-exponential factors of hydrochars decreased in the low-temperature section and increased in the high-temperature section.

Iron-based industries are one of the main contributors to greenhouse gas (GHG) emissions. Partial substitution of fossil carbon with renewable biocarbon (biomass) into the blast furnace (BF) process can be a sustainable approach to mitigating GHG emissions from the ironmaking process. However, the main barriers of using biomass for this purpose are the inherent high alkaline and phosphorous contents in ash, resulting in fouling, slagging, and scaling on the BF surface. Furthermore, the carbon content of the biomass is considerably lower than coal. To address these barriers, this research proposed an innovative approach of combining two thermochemical conversion methods, namely hydrothermal carbonization (HTC) and slow pyrolysis, for converting biomass into suitable biocarbon for the ironmaking process. Miscanthus, which is one of the most abundant herbaceous biomass sources, was first treated by HTC to obtain the lowest possible ash content mainly due to reduction in alkali matter and phosphorous contents, and then subjected to slow pyrolysis to increase the carbon content. Design expert 11 was used to plan the number of the required experiments and to find the optimal condition for HTC and pyrolysis steps. It was found that the biocarbon obtained from HTC at 199 °C for 28 min and consecutively pyrolyzed at 400 °C for 30 min showed similar properties to pulverized coal injection (PCI) which is currently used in BFs due to its low ash content (0.19%) and high carbon content (79.67%).

An activated carbon manufacturing process from winemaking waste is analyzed. In that way, vine shoots conversion is studied as a basis for plant designing, and mass and energy balances of hydrothermal carbonization and physical activation are fulfilled. To develop an energy-integrated plant, a network of heat exchangers is allocated to recover heat waste, and a cogeneration cycle is designed to provide electricity and remaining heat process demands. Furthermore, thermoeconomic analysis is applied to determine the thermodynamic efficiency and the economic viability of the plant. Energy balance indicates that heat exchangers energy integration covers 48.9% of the overall demands by crossing hot and cold streams and recovering heat from residual flue gas. On the other hand, the exergy costs analysis identifies combustion of pruning wood as the main source of exergy destruction, confirming the suitability of the integration to improve the thermodynamic performance. Attending to economic costs analysis, production scale and vineyard pruning wood price are identified as a critical parameter on process profitability. With a scale of 2.5 ton/h of pruning wood carbonization, a break-event point to compete with activated carbons from biomass origin is reached. Nevertheless, cost of pruning wood is identified as another important economic parameter, pointing out the suitability of wet methods such as hydrothermal carbonization (HTC) to treat them as received form the harvest and to contribute to cutting down its prices.

Hydrothermal carbonization (HTC) reactor systems used to convert wet organic wastes into value-added hydrochar are generally classified in the literature as liquid water-based (HTC) or vapor-based (VTC). However, the distinction between the two is often ambiguous. In this paper, we present a methodological approach to analyze process conditions for hydrothermal systems. First, we theoretically developed models for predicting reactor pressure, volume fraction of liquid water and water distribution between phases as a function of temperature. The reactor pressure model predicted the measured pressure reasonably well. We also demonstrated the importance of predicting the condition at which the reactor system enters the subcooled compression liquid region to avoid the danger of explosion. To help understand water–feedstock interactions, we defined a new solid content parameter %S(T) based on the liquid water in physical contact with feedstock, which changes with temperature due to changes in the water distribution. Using these models, we then compared the process conditions of seven different HTC/VTC cases reported in the literature. This study illustrates that a large range of conditions need to be considered before applying the label VTC or HTC. These tools can help in designing experiments to compare systems and understand results in future HTC research.

In many countries, sewage sludge is directly used for energy and agricultural purposes after dewatering or digestion and dewatering. In recent years, there has been a growing interest in additional upstream hydrothermal carbonization (HTC), which could lead to higher yields in the energetic and agricultural use. Twelve energetic and agricultural valorization concepts of sewage sludge are defined and assessed for Germany to investigate whether the integration of HTC will have a positive effect on the greenhouse gas (GHG) emissions. The study shows that the higher expenses within the HTC process cannot be compensated by additional energy production and agricultural yields. However, the optimization of the HTC process chain through integrated sewage sludge digestion and process water recirculation leads to significant reductions in GHG emissions of the HTC concepts. Subsequently, nearly the same results can be achieved when compared to the direct energetic use of sewage sludge; in the agricultural valorization, the optimized HTC concept would be even the best concept if the direct use of sewage sludge will no longer be permitted in Germany from 2029/2032. Nevertheless, the agricultural valorization concepts are not generally advantageous when compared to the energetic valorization concepts, as it is shown for two concepts.

Olive trimmings (OT) were used as feedstock for an in-depth experimental study on the reaction kinetics controlling hydrothermal carbonization (HTC). OT were hydrothermally carbonized for a residence time τ of up to 8 h at temperatures between 180 and 250 °C to systematically investigate the chemical and energy properties changes of hydrochars during HTC. Additional experiments at 120 and 150 °C at τ = 0 h were carried out to analyze the heat-up transient phase required to reach the HTC set-point temperature. Furthermore, an original HTC reaction kinetics model was developed. The HTC reaction pathway was described through a lumped model, in which biomass is converted into solid (distinguished between primary and secondary char), liquid, and gaseous products. The kinetics model, written in MATLABTM, was used in best fitting routines with HTC experimental data obtained using OT and two other agro-wastes previously tested: grape marc and Opuntia Ficus Indica. The HTC kinetics model effectively predicts carbon distribution among HTC products versus time with the thermal transient phase included; it represents an effective tool for R&D in the HTC field. Importantly, both modeling and experimental data suggest that already during the heat-up phase, biomass greatly carbonizes, in particular at the highest temperature tested of 250 °C.

Hydrochar is a very interesting product from agricultural and food production residues. Unfortunately, severe conditions for complete conversion of lignocellulosic biomass is necessary, especially compared to the conversion of sugar compounds. The goal of this work is to improve the conversion of internal carbohydrates by application of a two-steps process, by acid addition and slightly higher water content. A set of experiments at different temperatures (180, 200, and 220 °C), reaction times (2 and 4 h), and moisture contents (80% and 90%) was performed to characterize the solid (high heating value (HHV), elemental) and liquid product phase. Afterwards, acid addition for a catalyzed hydrolysis reaction during hydrothermal carbonization (HTC) and a two-steps reaction (180 and 220 °C) were tested. As expected, a higher temperature leads to higher C content of the hydrochar and a higher fixed carbon (FC) content. The same effect was found with the addition of acids at lower temperatures. In the two-steps reaction, a primary hydrolysis step increases the conversion of internal carbohydrates. Higher water content has no significant effect, except for increasing the solubility of ash components.

Peat moss and miscanthus were hydrothermally carbonized (HTC) either individually or co-processed in a different ratio to produce hydrochar. The hydrochar and pelletized hydrochar were then characterized to determine if hydrochar can be used as an alternative to coal to produce bioenergy from existing coal-fired power plants in Ontario that have already been shut down. The properties of carbonized biomass (either hydrochar or pellets) reveal that fuel grade hydrochar can be produced from peat moss or from the blend of peat moss and miscanthus (agricultural biomass/energy crops). Hydrochar either produced from peat moss or from the blend of peat moss and miscanthus was observed to be hydrophobic and porous compared to raw peat moss or raw miscanthus. The combustion indices of carbonized biomass confirmed that it can be combusted or co-combusted to produce bioenergy and can avoid slagging, fouling, and agglomeration problems of the bioenergy industry. The results of this study revealed that HTC is a promising option for producing solid biofuel from undervalued biomass, especially from high moisture biomass. Co-processing of peat moss with rural biomass, a relatively novel idea which can be a potential solution to heat and power for the rural communities/agri-industry that are not connected with national grids and alleviate their waste management problems. In addition, the hydrochar can also be used to run some of the existing coal-fired power plants that have already been shut down in Ontario without interrupting investment and employment.

Hydrothermal carbonization (HTC) is a promising technology to convert wet biomass into carbon-rich materials. Until now, the chemical processes occurring and their influence on the product properties are not well understood. Therefore, a target-oriented production of materials with defined properties is difficult, if not impossible. Here, model compounds such as cellulose and lignin, as well as different definite biomasses such as straw and beech wood are converted by hydrothermal carbonization. Following this, thermogravimetic (TGA) and FTIR measurements are used to get information about chemical structure and thermal properties of the related hydrochars. Some of the isolated materials are thermally post-treated (490 °C and 700 °C) and analyzed. The results show that at “mild” HTC conversion, the cellulose part in a lignocellulose matrix is not completely carbonized and there is still cellulose present. Thermal post-treatment makes the properties of product materials more similar and shows complete carbonization with increase aromatic cross-linking, proven by TGA and FTIR results.

Hydrothermal carbonization (HTC), as an environmental friendly process, presents wide potential applicability for converting biomass to biochar with high energy density. Reed, a major energy crop, was converted by a HTC process in a batch reactor at 200–280 °C for 0.5 to 4 h. Biochar mass yield changed from 66.7% to 19.2% and high heating value (HHV) from 20.0 kJ/g to 28.3 kJ/g, respectively, by increasing the carbonization temperature from 200 °C to 280 °C and decreasing the residence time from 2 h to 1 h. The Fourier Transform infrared spectroscopy (FTIR), X-ray Diffraction (XRD), and Scanning Electron Microscope (SEM) results indicated the lignocellulosic crosslink structure of reed is broken and biochar having a high energy density is obtained with the increase of temperature. The microcrystal features of reed are destroyed and biochar contained mainly lignin fractions. The HTC of biocrude is carried out at 200–280 °C for 2.0 h and the results showed that the obtained biochar has uniform particles filled with carbon microspheres.

In this paper, a hydrothermal carbonization (HTC) process is designed and modeled on the basis of experimental data previously obtained for two representative organic waste materials: off-specification compost and grape marc. The process accounts for all the steps and equipment necessary to convert raw moist biomass into dry and pelletized hydrochar. By means of mass and thermal balances and based on common equations specific to the various equipment, thermal energy and power consumption were calculated at variable process conditions: HTC reactor temperature T: 180, 220, 250 °C; reaction time θ: 1, 3, 8 h. When operating the HTC plant with grape marc (65% moisture content) at optimized process conditions (T = 220 °C; θ = 1 h; dry biomass to water ratio = 0.19), thermal energy and power consumption were equal to 1170 kWh and 160 kWh per ton of hydrochar produced, respectively. Correspondingly, plant efficiency was 78%. In addition, the techno-economical aspects of the HTC process were analyzed in detail, considering both investment and production costs. The production cost of pelletized hydrochar and its break-even point were determined to be 157 €/ton and 200 €/ton, respectively. Such values make the use of hydrochar as a CO2 neutral biofuel attractive.